Kits and methods for fiber composites including partially-cured resinous materials for the reinforcement of physical structures

ABSTRACT

A composite system for the reinforcement of physical structures includes a plurality of unidirectional fibers arranged with respective longitudinal axes generally parallel to each other over a substantial portion of a length of each unidirectional fiber. The plurality of unidirectional fibers are non-mechanically connected. A resinous material adheres the plurality of unidirectional fibers to each other such that each one of the plurality of unidirectional fiber is adhered to at least one adjacent one of the plurality of unidirectional fibers along a substantial portion of the length of the adjacent one of the plurality unidirectional fibers.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.14/603,176, filed Jan. 22, 2015, which claims priority to and thebenefits of U.S. Patent Application No. 61/930,796, filed Jan. 23, 2014,and U.S. Patent Application No. 61/985,058, filed Apr. 28, 2014, each ofwhich are hereby incorporated by reference herein in their entireties.

TECHNICAL FIELD

The present disclosure relates generally to the repair and reinforcementof structures, and more particularly to composite systems for the repairand reinforcement structures.

BACKGROUND

Conduit assemblies, such as pipelines and hydraulic circuits, are usedto transport an assortment of fluids, such as water, oil, variousnatural and synthetic gases, sewage, slurry, hazardous materials, andthe like. Similar structures are utilized for transmitting electricaland fiber optic cabling across vast expanses of land in establishingtelecommunication networks. Conduit assemblies are formed from a varietyof materials, including, for example, concrete, plastic (e.g., polyvinylchloride, polyethylene), and various metallic materials, such as iron,copper, and steel. Containment structures, such as storage tanks, areused to store an assortment of fluids, such as oil, water, chemicals,various natural and synthetic fluids, sewage, hazardous materials, andthe like. Containment structures are formed from a variety of materials,including concrete, plastic, and metallic materials, such as iron,copper, aluminum, and steel. Structures used to support variousbuilding, industrial, and highway structures, such as columns and beams,are constructed from various construction materials, such as wood,reinforced concrete, unreinforced concrete, aluminum, iron, and steel.

Conduit assemblies, containment structures, building structures, andhighway structures are often exposed to harsh environments and are oftenunder loads that can cause the assemblies and structures to degrade tothe point of needing to be repaired or structurally reinforced. Thus,there is a need for improved repair and reinforcement systems that arequick, versatile, durable, minimally disruptive, and cost-effective.

SUMMARY

According to one aspect of the present invention, a composite system forthe reinforcement of physical structures comprises a plurality ofunidirectional fibers each having a longitudinal axis and a length. Theplurality of unidirectional fibers are of approximately equal length andarranged with the respective longitudinal axes generally parallel toeach other over a substantial portion of the length of eachunidirectional fiber. The plurality of unidirectional fibers arenon-mechanically connected. A resinous material adheres the plurality ofunidirectional fibers to each other such that each one of the pluralityof unidirectional fiber is adhered to at least one adjacent one of theplurality of unidirectional fibers along a substantial portion of thelength of the adjacent one of the plurality unidirectional fibers.

According to another aspect of the present invention, a method ofmanufacturing a composite system for the reinforcement of physicalstructures includes a plurality of unidirectional fibers and a resinousmaterial adhering the plurality of unidirectional fibers to each other.The method comprises providing a first supply roll including adisposable applicator film. A first plurality of individual supplyspools of first unidirectional fibers is provided. Each unidirectionalfiber has a first longitudinal axis. The first individual supply spoolsof first unidirectional fibers are arranged adjacent to each other. Thedisposable applicator film is extended from the first supply roll to asecond collector roll. The first unidirectional fibers are extended fromthe first individual supply spools such that the first unidirectionalfibers are parallel to each other and are disposed above or below thedisposable applicator film. During the extending of the disposableapplicator film and the extending of the first unidirectional fibers,the resinous material is applied to the first unidirectional fibersalong the width of each of the first unidirectional fibers such that theresinous material is generally evenly applied and impregnates the firstunidirectional fibers such that the first unidirectional fibers adhereto each other. The resin impregnated first unidirectional fibers areplaced on the disposable applicator film. The adhered firstunidirectional fibers are generally parallel to each other. Each of thefirst unidirectional fibers are adhered to at least one adjacent one ofthe first unidirectional fibers along a substantial portion of theadjacently adhered fibers such that the first unidirectional fibers arenon-mechanically bound to each other.

In a yet another aspect of the present invention, a composite system forthe reinforcement of physical structures comprises a plurality of firstunidirectional fibers each having a first longitudinal axis and a firstlength. The plurality of first unidirectional fibers are ofapproximately equal length and arranged with the respective firstlongitudinal axes generally parallel to each other over a substantialportion of the first length of each first unidirectional fiber. Aplurality of second unidirectional fibers each having a secondlongitudinal axis and a second length. The plurality of secondunidirectional fibers are of approximately equal length and arrangedwith the respective second longitudinal axes generally parallel to eachother over a substantial portion of the second length of the secondunidirectional fibers. The second length is less than the first length.A resinous material adheres the plurality of first unidirectional fibersto each other such that each of the plurality of first unidirectionalfibers is adhered to at least one adjacent one of the plurality of firstunidirectional fibers along a substantial portion of the first length ofthe adjacent first unidirectional fibers thereby forming a firstunidirectional fiber layer of generally non-mechanically connected firstunidirectional fibers to define a first plane. The resinous materialfurther adheres the plurality of second unidirectional fibers to eachother such that each of the plurality of second unidirectional fibers isadhered to at least one adjacent one of the plurality of secondunidirectional fibers along a substantial portion of the second lengthof the adjacent second unidirectional fibers thereby forming a secondunidirectional fiber layer of generally non-mechanically connectedsecond unidirectional fibers to define a second plane. The plurality ofsecond unidirectional fibers are oriented such that any one of thesecond longitudinal axes in the second plane is skew to any one of thefirst longitudinal axes in the first plane. The first unidirectionalfiber layer and the second unidirectional fiber layer arenon-mechanically connected.

In a yet another aspect of the present invention, a composite system forthe reinforcement of physical structures comprises a firstunidirectional fiber layer including a plurality of non-mechanicallyconnected first unidirectional fibers each having a first longitudinalaxis and a first length. The plurality of first unidirectional fibersare of approximately equal length and arranged with the respective firstlongitudinal axes generally parallel to each other over a substantiallythe entire first length of each first unidirectional fiber. Theplurality of first unidirectional fibers include electrically and/orheat conductive materials. The plurality of first unidirectional fibersare adhered to each other by a resinous material such that each of theplurality of first unidirectional fibers is adhered to at least oneadjacent one of the plurality of first unidirectional fibers alongsubstantially the entire first length of an adjacent firstunidirectional fiber. A second insulating fiber layer is adhered to thefirst unidirectional fiber layer by the resinous material and/or anotherresinous material. The second insulating layer separates theelectrically and/or heat conductive material(s) in the firstunidirectional fiber layer from direct contact with an electricallyand/or heat conductive physical structure being reinforced by thecomposite system.

Additional aspects of the invention will be apparent to those ofordinary skill in the art in view of the detailed description of variousembodiments, which is made with reference to the drawings, a briefdescription of which is provided below.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A-1C illustrate an application of a unidirectional fibercomposite system for reinforcing an exemplary physical structure inaccordance with aspects of the present invention.

FIG. 2 illustrates an exemplary multi-layer unidirectional fibercomposite system for reinforcing physical structures in accordance withaspects of the present invention.

FIGS. 3A-3E illustrate an application of a multilayer composite systemfor reinforcing physical structure that includes a combination ofunidirectional fiber and/or non-unidirectional fiber layers inaccordance with aspects of the present invention.

FIG. 4 illustrates an exemplary method and system for making a compositesystem including a plurality of unidirectional fibers and a resinousmaterial for adhering the plurality of unidirectional fibers to eachother in accordance with aspects of the present invention.

While the invention is susceptible to various modifications andalternative forms, specific embodiments have been shown by way ofexample in the drawings and will be described in detail herein. Itshould be understood, however, that the invention is not intended to belimited to the particular forms disclosed. Rather, the invention is tocover all modifications, equivalents, and alternatives falling withinthe spirit and scope of the invention as defined by the appended claims.

DETAILED DESCRIPTION

While this invention is susceptible of embodiment in many differentforms, there is shown in the drawings and will herein be described indetail preferred embodiments of the invention with the understandingthat the present disclosure is to be considered as an exemplification ofthe principles of the invention and is not intended to limit the broadaspect of the invention to the embodiments illustrated. For purposes ofthe present detailed description, the singular includes the plural andvice versa (unless specifically disclaimed); the word “or” shall be bothconjunctive and disjunctive; the word “all” means “any and all”; theword “any” means “any and all”; and the word “including” means“including without limitation.”

Referring now to FIGS. 1A-1C, an exemplary aspect of a unidirectionalfiber composite system is illustrated for reinforcing a physicalstructure 130, which in this instance, is shown with the unidirectionalfiber composite system being applied around an outer surface 133 of ametal pipe. A unidirectional fiber composite system includes a pluralityof unidirectional fibers, such as unidirectional fibers 112 a-112 n,each having a longitudinal axis and a length, that in the case of FIGS.1A-1C, are arranged to be parallel to the long or longitudinal axis 114of the unidirectional fiber composite system 110. The plurality ofunidirectional fibers 112 a-112 n are of an approximately equal lengthand are arranged with their respective longitudinal axes generallyparallel to each other over a substantial portion of the length of eachunidirectional fiber.

The plurality of unidirectional fibers are non-mechanically connectedusing a resinous material that adheres the plurality of unidirectionalfibers to each other. For example, in some aspects, the resinousmaterial causes or provides an initial level of stickiness between theunidirectional fibers, such as through a thick viscosity of the resin,that provides some mechanical integrity initially while the resin is inthe uncured state but when the resin cures it transitions into a hardmatrix once curing is finished so that there is essentially anon-mechanical connection (e.g., no direct mechanical connection)between the unidirectional fibers, and instead the cured resin matrixholds or bonds the unidirectional fibers together. In other aspects,such as with select epoxy resins, the unidirectional fibers may, for themost part, be held or bonded to each other via the hard or semi-hardenedresin matrix before the resin has fully cured. Each one (or almost everyone) of the plurality of unidirectional fibers is adhered to an adjacentone of the plurality of unidirectional fibers along a substantialportion of the length of the adjacent unidirectional fiber. In someaspects, the plurality of unidirectional fibers of the composite systemare generally parallel to each other and have an uncured resinousmaterial adhering them together. The plurality of unidirectional fibers112 a-112 n can be placed such that the fibers rest on a disposableplastic applicator film 120 (e.g., adhered through the stickiness of athick viscous resin in an uncured state) that can assist with themanufacturing, storage, and application of the resinous unidirectionalfiber composite system. For example, an unused unidirectional fibercomposite system can be stored as a rolled-up kit 140 that can beunrolled as the unidirectional fibers adhered via the resinous materialare applied to a physical structure (e.g., containment systems,pipelines and conveyance systems, or load bearing structures such ascolumns or beams, metal structures, concrete structures) and theapplicator film 120 is separated from the unidirectional fibers 112a-112 n.

In FIG. 1B, after initially unrolling the rolled-up kit 140 where resinimpregnated unidirectional fibers 112 a-112 n rest on the applicatorfilm 120, the uncured, resin-impregnated unidirectional fibers 112 a-112n are then applied to the physical structure 130 (e.g., the metal pipe).The plastic applicator film 120 can be a disposable film which ispartially removed as further illustrated between FIGS. 1B and 1C as theresin-impregnated unidirectional fibers 112 a-112 n of the compositesystem 110 are wrapped around the structure. The adhered unidirectionalfibers 112 a-112 n then continue to be wrapped as illustrated in FIG.1C.

In some aspects, a single layer of adhered unidirectional fibers may beapplied to the structure. In another aspect, multiple generallyoverlying layers of adhered unidirectional fibers can be applied from asingle continuous roll or from multiple rolls of the unidirectionalfiber composite systems. For example, from the same continuous roll thatis applied in FIG. 1C, a first layer 110 a of adhered resin-impregnatedunidirectional fibers are overlain by a second layer 110 b, 110 c alsoapplied from the same continuous roll. The unidirectional fibercomposite system can also be wrapped around a structure using partiallyoffset, overlapping layers. The application of the composite system to astructure and the type of composite system will vary depending on thedesired properties and extent of the structural repair or reinforcement.

In some desirable aspects of a unidirectional fiber composite system,the unidirectional fibers are non-mechanically connected, such thatthere is no direct mechanical connection between adjacent fibers. Forexample, the fibers may be adhered through impregnation of theunidirectional fibers with a resinous material, such as a polyurethaneor epoxy resin. The resinous material used to adhere the plurality ofgenerally parallel unidirectional fibers may also be used to adhere orotherwise attach the unidirectional fiber composite system to thephysical structure being repaired or reinforced. By adheringunidirectional fibers together such that they are generally parallel toone another, the uniqueness of the alignment of the unidirectionalfibers to one another is maximized and allows for the generally straightalignment of the adhered unidirectional fibers in the composite system.

One beneficial aspect of maintaining the straight alignment of thefibers in the composite system is that the tensile properties of theplurality of unidirectional fibers are maximized by minimizing kinking,bending, or otherwise weakening their tensile strength. Maintaining thegenerally straight alignment further offers the benefit of minimizingthe thickness of the composite system for the reinforcement of thephysical structure. For example, each layer of reinforcement wrappedover or around a given cross-section of reinforced structure (e.g., apipe, a column) minimally increases the cross-sectional dimension of thestructure. The increase in cross-section for a repair or reinforcementis generally due to the increase in diameter (for example, for acircular pipe or column) caused by the unidirectional fibers or thelayering of unidirectional fibers used in the composite system. Thus, adesirable aspect of having a composite system where the tensilestiffness and strength properties of the fibers can be maximized is thatthe quantity of fibers needed to obtain the desired reinforcementproperties is decreased.

Some non-limiting examples of unidirectional fibers that can be used fora unidirectional fiber composite system include carbon fibers (e.g.,both pan and pitch based), glass fibers (e.g., fiber glass), basaltfibers, aramid fibers, metal fibers, or any combinations thereof.

Some non-limiting example of resins used to adhere adjacentunidirectional fibers and to adhere overlying unidirectional fiberlayers include polyurethane, polyurea, epoxy, polyimide,polyoxazolidones, silanes, vinyl ester resins, and/or any one, two, ormulticomponent resin systems. In some aspects, it is desirable for theresins to initially be in an uncured or partially cured state prior tothe composite system being applied to structure targeted forreinforcement. Then the resin can be configured to subsequently cureinto a rigid or semi-rigid state after the composite system has beenapplied to the structure. In some aspects, the resins include apolyurethane material having an aliphatic prepolymer. In some aspects,the resins can include a polyurethane material having an aliphaticisocyanate prepolymer. In some aspects, the resins can include apolyurethane material having an isocyanate prepolymer. In some aspects,the resins (e.g., one with an aliphatic isocyante prepolymer) include apolyurethane material chemically configured to activate and harden afterremoval from a generally inert environment and exposure to humid air,moisture-borne air, or an environment that otherwise provided moistureto activate the resin.

Other non-limiting exemplary aspects of resins contemplated for theunidirectional fiber composite system include the resins described inU.S. Pat. No. 4,519,856, issued May 28, 1985, entitled, “Resin-ClothStructural System”; U.S. Pat. No. 5,030,493, issued Jul. 9, 1991,entitled, “High Strength Resin-Cloth Structural System”; U.S. Pat. No.8,522,827, issued Sep. 3, 2013, entitled, “Protective Seal For APipeline Assembly”; U.S. Patent Application Publication No.2010/0237606, published Sep. 23, 2010, entitled, “End Seal For APipeline”; U.S. Patent Application Publication No. 2012/0001393,published Jan. 5, 2012, entitled, “Deformable Composite Plug”; U.S.Patent Application Publication No. 2012/156378, published Jun. 21, 2012,entitled, “Systems, Methods, and Device For Applying Fluid Composites ToCarrier Sheets”; and U.S. Patent Application Publication No.2013/0160926, published Jun. 27, 2013, entitled, “Systems, Methods, andDevice For Strengthening Fluid System Components Using Radiation-CurableComposites”; the disclosures of which are each hereby incorporated byreference herein in their entireties.

Other non-limiting aspects of resins contemplated for unidirectionalfiber composite systems include the resins incorporated into theresin-impregnated products manufactured and sold by Neptune Research,Inc. of Riviera Beach, Fla., USA (formerly located in Lake Park, Fla.,USA), including the resins and/or the resins in the resin-impregnatedproducts available under the trade names SYNTHO-GLASS®, SYNTHO-GLASS®NP, SYNTHO-GLASS® 24, SYNTHO-GLASS XT®, VIPER-SKIN®, TITAN® 118, TITAN®218, TRANS-WRAP™, TITAN® SATURANT EPDXY, THERMO-WRAP™, THERMO-WRAP™ CF,SOLAR-WRAP™, and SYNTHO-PDXY™ HC.

A unidirectional fiber composite system with uncured resins can bestored or packaged as part of a repair kit in a moisture-tight andsealed pouch. The composite system kit can have a wide range of storagetemperatures that will typically be determined by the type of resin usedto adhere the unidirectional fibers and a temperature range that retainsthe resin in its uncured state prior to a repair or reinforcementapplication.

In some aspects, it is contemplated that the resin to unidirectionalfiber ratios, by volume, range from about 80:20 to 20:80. In someaspects, the resin to fiber ratio, by volume, ranges from about 60:40 to20:80. In some aspects, the composite system width (e.g., the entirewidth of the fiber tape illustrated in FIG. 1B from fiber 112 a through112 n) can range from approximately ½ inch to approximately 24 inches(approximately 1 cm to approximately 60 cm), where the width will varydepending on the application. For composite systems based onunidirectional carbon fibers, the modulus of elasticity of the compositesystem can range from between about 12 to about 150 megapounds persquare inch (Msi) (about 82 GPa to about 1034 GPa). For compositesystems based on unidirectional glass fibers, the modulus of elasticityof the composite system can range from about 5 to about 13 Msi (about 34GPa to about 90 GPa).

A single layer of a unidirectional fiber composite system 110 will havea thickness that varies primarily based on the fiber thickness andsecondary on the type of resin. In some aspects, a unidirectional fibercomposite system can have a thickness of less than about 1/16 of an inch(less than about 2 mm). In some aspects, a unidirectional fibercomposite system has a thickness less than or equal to about 100 mils(less than or equal to about 2.5 mm), less than or equal to about 50mils (less than or equal to about 1.3 mm), less than or equal to about25 mils (less than or equal to about 0.6 mm), less than or equal toabout 15 mils (less than or equal to about 0.4 mm), less than or equalto about 10 mils (less than or equal to about 0.3 mm), less than orequal to about 5 mils (less than or equal to about 0.1 mm), between therange of about 50 to 100 mils (about 1.3 to 2.5 mm), between the rangeof about 25 to 50 mils (about 0.6 to 1.3 mm), between the range of about10 to 25 mils (about 0.3 to 0.6 mm), and/or between the range of about 5to 10 mils (about 0.1 to 0.3 mm).

As demonstrated by some of the desirable thickness and strength aspectsof a unidirectional fiber composite system, such systems provide a highstiffness and high strength reinforcement system that minimizes theincrease in thickness of the reinforced or repaired structure, even forapplications where multiple layers of composite unidirectional fibersare applied to the portion of the structure being repaired orreinforced.

The different types of structures and geometries to which the describedcomposite system may be applied to include steel columns (e.g., flange,hollow tube, hollow square, hollow rectangular cross-sections); concretecolumns (e.g., circular, oval, square, rectangular cross-section);concrete or steel beams; other load bearing structures made of steel,wood or concrete; pipes; pipelines; storage tanks; other containmentstructures; concrete walls; and/or concrete slabs. Concrete structurescan include reinforced or unreinforced concrete structures. Aunidirectional fiber composite system can be applied either to theinside of a structure (e.g., inside the pipe of a pipeline) orexternally (e.g., the exterior of a pipe, bonded to the exterior of aconcrete structure, bonded to the flange of a steel column).

In some aspects, resins contemplated for a unidirectional fibercomposite system are curable under water or in the air. It is furthercontemplated that in some aspects resins can be cured at temperaturesabove 400 degree F. or below 50 degrees F. In some aspects, resins forthe described composite system can be moisture cured, aqueous solutioncured, light cured (e.g., UV light curable), electron-beam cured, orheat cured (e.g., thermoset).

In one exemplary aspect, the unidirectional fiber composite system ismade with carbon fibers that are arranged such that the carbon fibersare generally parallel to each other prior to a resinous material beingapplied to the fibers. In some aspects, individual carbon fibers have adiameter that is between about 0.0001 inches and 0.005 inches (betweenabout 2.5 micrometers and 127 micrometers). In some aspects, individualcarbon fibers have a diameter value that is between about 0.0002 inchesand 0.0004 inches (between about 5 micrometers and about 254micrometers). Other fibers of other diameters are also contemplated. Forexample, in some aspects, a unidirectional fiber composite system ismade with glass fibers (e.g., fiberglass) that are arranged such thatthe glass fibers are generally parallel to each other prior to aresinous material being applied to the fibers. In some aspects,individual glass fibers can have a diameter value that is between about0.0002 inches and 0.001 inches (between about 5 micrometers and 25micrometers). In some aspects, a unidirectional fiber composite systemis made with basalt fibers that are arranged such that the basalt fibersare generally parallel to each other prior to a resinous material beingapplied to the fibers. In some aspects, individual basalt fibers canhave a diameter that is between about 0.0002 inches and 0.001 inches(between about 5 micrometers and 25 micrometers). Prior to fabricatingan uncured unidirectional fiber composite system and applying theresinous material, the unidirectional fibers can be stored on supplyspools from which the unidirectional fibers would be extended such thatthe fibers are generally parallel to each other during the manufacturingof the described composite systems (see FIG. 4).

Referring now to FIG. 2, an exemplary multi-layer unidirectional fibercomposite system 200 for reinforcing physical structures is illustrated.The system includes a plurality of unidirectional fiber layers (e.g.,210, 220, 230, 240) adhered to each other (e.g., connected by a layer ofresin), with the fibers in each layer of unidirectional fibers beingoriented at different angles to the fibers in the adjacent layer. Insome aspects, the fibers between adjacent layers are oriented inapproximately the same direction (not illustrated). In contrast to awoven fabric that has interwoven fibers at different angles to eachother, the individual unidirectional fiber layers (e.g., 210, 220, 230,240) in FIG. 2 are each distinct layers that are non-mechanicallyconnected (e.g., without any entanglement or direct connection betweenthe fibers of the distinct layers). In some aspects, resinous materials,such as those described elsewhere herein, are used to adhere or bond theunidirectional fiber layers (e.g., 210, 220, 230, 240) to each other.

Each of the unidirectional fiber layers (e.g., 210, 220, 230, 240) ofthe multi-layer unidirectional fiber composite system 200 can be pressedtogether or otherwise laminated or adhered, such as through the same orsimilar resinous materials that adhere the individual fibers togetherfor the respective distinct unidirectional fiber layers (e.g., 210, 220,230, 240). As illustrated in FIG. 2, the individual fibers (e.g., 212,222, 232, 242) of each respective layer (e.g., 210, 220, 230, 240) areskew to the fibers in the unidirectional fiber layer immediately aboveor below. While the angle of the skew will vary depending on thereinforcement application, for illustrative purposes the individualfibers between the adjacent layers are skewed by approximately 45degrees from the fibers in the adjacent layer. To maintain theindividual strength that each layer possess along the direction parallelto each layers respective unidirectional fibers, the interface (e.g.,215, 225, 235) between each of the adjacent layers (e.g., 210, 220, 230,240) provides for each of the layers to be adjacent to each other, butno provision is made to mechanically connect the adjacent layers so thatany kinking or other weakening of the unidirectional fibers occurs. Asdiscussed above, to maintain the non-mechanical nature of the connectionbetween adjacent layers (e.g., 210, 220, 230, 240), they may belaminated together or otherwise adhered using a resinous material. Forexample, the adjacent layers may be saturated with resin and placed oneach other while the resin(s) are uncured. In some aspects, the layer(s)may then be consolidated with rollers that apply pressure to the layerduring the application stage to remove any air voids in the interface.It is contemplated that additional resin(s) may or may not be applied tojoin adjacent layers depending, for example, on the level of saturationof the individual fiber layers.

Referring now to FIGS. 3A-3E an application of a multilayer compositesystem for reinforcing a physical structure that includes a combinationof unidirectional fiber and non-unidirectional fiber layers isillustrated. A combination of unidirectional and non-unidirectionalfiber layers in a composite reinforcement system may be desirable indifferent applications, such as where an electrically non-conductive orheat insulating layers are preferred. For example, the physicalstructure (e.g., 330) being reinforced may be a conductive metal pipe orpipeline and it is desirable to separate a reinforcing layer ofunidirectional carbon fibers adhered with a resin from the metal pipethat is being reinforced. In some aspects, the unidirectional fiberlayer may include non-conductive fibers (e.g., glass, fibers, basaltfibers, aramid fibers), electrically and/or heat conductive fibers(e.g., metallic fibers, carbon fibers), or combinations thereof.

Similar to the unidirectional fiber composite systems described above,the unidirectional fiber layer may include unidirectional fibers thatare arranged adjacent to and generally parallel to each other. Theindividual unidirectional fibers can be adhered to one another by aresin, where the individual fibers are generally non-mechanicallyconnected to each other, but rather connected or adhered via the resinmatrix that holds or bonds the unidirectional fibers together.Maintaining a non-mechanical connection, or at least minimizingmechanical interactions (e.g., direct mechanical interactions) betweenthe individual unidirectional fibers, can be desirable so that thetensile properties of the unidirectional fibers are not compromised suchthat any potential reduction in the tensile strength of a unidirectionalfiber is minimized. Tensile properties of the unidirectional fibers canbe compromised due to kinking, bending, or other weakening effects thatcould occur through mechanical-type connections between adjacentunidirectional fibers.

While some aspects of composite systems may include unidirectional fiberlayer(s) being adhered to one another or being used alone to reinforce aphysical structure, it is contemplated that in certain aspects aunidirectional fiber layer (e.g., layer 370 in FIGS. 3C to 3E) may beadhered with a resinous material to non-unidirectional fiber layer(e.g., a fiber layer including woven fibers or mat fibers), such aslayer 360 in FIGS. 3B to 3E). This can be desirable for certainapplications of composite systems involving a repair or reinforcement ofphysical structures that are electrically and/or heat conductive (e.g.,metal pipes; heat-conductive conveyances). Such repairs orreinforcements may have additional criteria for a proper reinforcementwhere a unidirectional fiber layer application using conductive fibers(e.g., metal fibers, carbon fibers), whether electrically or thermallyconductive, is desirable but the unidirectional fiber reinforcementlayer is preferably insulated from the conductive physical structurethat is being repaired or reinforced. In such instances, it would bedesirable to have a multi-layer composite system wrapped around orotherwise applied to the physical structure (e.g., pipe) that is beingreinforced or repaired. The composite system can include the conductiveunidirectional fiber layer (e.g., layer 370) being separated from theelectrical and/or heat conductive physical structure (e.g., 330) by oneor more insulating layers (e.g., such as fiberglass layer or a similarnon-conductive layer 360).

In some aspects, an insulating layer (e.g., layer 360) may includeunidirectional fibers. However, other types of fiber layers are alsocontemplated, such as an insulating woven fiber layer, other types ofnon-woven fiber layers, mat fiber layers, or fiber layers includingcombinations woven, non-woven, or mat fibers. The fiber materials for anelectrical and/or heat insulating layer can include, among others, glassfibers (e.g., fiberglass), basalt fibers, aramid fibers, para-aramidsynthetic fibers, or combinations thereof. The conductive unidirectionalfiber layer, while being placed or wrapped around the insulating layer,is preferably adhered to the insulating layer with a resinous materialrather than through a mechanical connection. The use of the resin toadhere the different layers can be desirable for maintaining theintegrity and minimizing any compromise of to the tensile properties ofthe unidirectional fiber layer.

In some aspects, the insulating layer may directly separate theconductive unidirectional fiber layer and the conductive structure beingreinforced. It is also contemplated that an optional third layer ofmaterial may be placed between the insulating layer and the conductivestructure. In the exemplary aspect of a conductive structure (e.g., ametal pipe), a multi-layer composite system can comprise three layerscombined into a single wrap. A first or top layer includes a conductiveunidirectional fiber layer having its bottom side adhered to a top sideof an insulating second layer. A third, or bottommost, layer cancomprise an adhesive, a primer layer, an insulative coating, a gelmaterial, and/or another coating that is in contact with a bottom sideof the insulating second layer (i.e., the side that is not adhered tothe unidirectional fiber layer). The three-layer composite system canthen be applied to a conductive structure that is the subject of repairor reinforcement. The third, or bottommost, layer of the multi-layercomposite system is placed in direct contact with the conductivestructure as the composite system is applied to the structure. Thecomposite system wrap will therefore include the insulating layerdisposed in direct contact with the third layer and the unidirectionalfiber layer disposed in direct contact with the insulating layer suchthat the insulating layer separates the unidirectional fiber layer andthird layer.

In some aspects, the composite reinforcement system comprises an outerunidirectional fiber layer (e.g., unidirectional carbon fibers adheredwith resin or other conductive fibers adhered with resin) and aninsulating layer below the outer layer (e.g., a fiberglass layer made ofunidirectional, woven, or mat fibers adhered with a resin) that isplaced onto (e.g., wrapped) the physical structure that is beingreinforced. An optional primer or adhesive layer that may or may not beanother insulating-type layer can be placed between the physicalstructure and the insulating layer immediately below the outer layer. Insome aspects, the third layer is a non-conductive layer that does not orresists conducting heat and/or electricity. Between each of the layers(e.g., the outer reinforcing layer above the insulating layer) resinonly is applied or is present via the adhering resins for the individuallayers such that each of the respective layers are non-mechanicallyconnected to each other so that the strength of the unidirectionalfibers is not decreased to kinking or other weakening of the fibers. Itis also contemplated that in some aspects the insulating layer below theouter layer can be pre-impregnated with resin or it can be fieldimpregnated with the resin.

In FIG. 3A, an example of the application of the primer layer 350 (or insome aspects an insulating primer layer, an insulating coating, or aninsulating gel) to an outer surface 333 of a physical structure 330 isillustrated. The primer layer 350 may be applied or spread using a brush340 or other types of application device for fluid or semi-fluidmaterials. After the primer layer 350 is applied, in FIG. 3B, aninsulating layer 360, such as a resin-impregnated fiberglass layer or alayer that includes otherwise insulating fibers and/or resins, isapplied above the primer layer 350, and thus, applied to the physicalstructure 330 being reinforced or repaired. The insulating layer 360 maybe part of a roll-up kit 365 that includes a disposable plastic filmapplicator. Once the insulating layer is fully applied to the physicalstructure 330 above the optional primer layer, the resin-impregnatedunidirectional fiber layer 370 is applied to the insulating layer 360.Similar to the insulating layer, the resin-impregnated unidirectionalfiber layer 370 may be a part of a roll-up kit 375 that includes adisposable plastic film applicator. With only resin separating theinsulating layer 360 and the outer resin-impregnated unidirectionalfiber layer 370, the outer layer 370 is wrapped or otherwise applied toreinforce the physical structure 330.

In some aspects, layer 350 may not be applied in the field (e.g., is notbrushed on) to a physical structure, but rather may be a part of amultilayer composite. For example, layer 350 could include a gelmaterial that is part of a rolled up, uncured composite system where thegel was pre-adhered or pre-applied to the insulating layer 360 as partof making the roll-up kit 365.

FIG. 3D illustrates one exemplary aspect of a finished multi-layercomposite system, including an outer resin-impregnated unidirectionalfiber layer 370, that reinforces a physical structure 330. While the topunidirectional fiber layer 370 may be illustrated extending nearly orover the lower layers, it is also contemplated that any conductivelayers, such as a metal pipe being reinforced and a reinforcement layerincluding conductive materials (e.g., unidirectional carbon fibers,unidirectional metal fibers), will be fully separated by an intermediateinsulating layer (e.g., layer 360) without any direct connection of thetwo conductive layers. The outer unidirectional fiber layer illustratedin FIG. 3D includes a plurality of generally parallel fibers 372 a-372 nthat are adhered with a resin that fills the void space 374 between theindividual fibers. Similarly, the interfaces 354, 364 also includeresins so that there is a non-mechanical connection between adjacentlayers, in particular, between the unidirectional fiber layers and anyadjacent layers. FIG. 3E illustrates an exploded view of all the layersapplied to the physical structure 330 in FIGS. 3A-3D including theoptional primer layer 350, the insulating layer 360, and the outerunidirectional fiber layer 370.

It is contemplated that the individual layers of a multi-layer compositesystem (e.g., see FIGS. 2 and 3A-3E) are pre-adhered to one another suchthat when the composite systems are applied to a structure theapplication is effectively done a single application of the multi-layersystem. For example, rather than each individual layer of themulti-layer system being individually applied to the physical structureundergoing a repair, each layer of the multi-layer composite system isalready pre-adhered so that one single wrap is applied to the structure.The single wrap includes all the adhered layers of the composite system.

FIG. 4 illustrates an exemplary method and system for making an uncuredcomposite system (e.g., a roll-up kit) that includes a plurality ofunidirectional fibers and a resinous material for adhering the pluralityof unidirectional fibers to each other. In some aspects, unidirectionalfibers (e.g., 415 a-415 f) are stored on one or more spools 410. Theunidirectional fibers on the individual spools may be single fibers, ormore typically a group of fibers, that extended from the respectivespool(s). The extended fibers are then aligned so that the plurality ofunidirectional fibers are generally (e.g., almost or usually) parallelto each other as the fibers align at roller 420 to form a thin layer(e.g., the thickness of a single fiber diameter; the thickness of nomore than several fiber diameters; the thickness of less than ten fiberdiameters) of adjacent unidirectional fibers (e.g., 415 a-415 f).

The thin layer of adjacent, generally parallel, unidirectional fibersare then subsequently moved through rollers 422 a-422 c which are partof a resin application basin 450. The resin application basin 450 canhave a resin supply hose 454 for discharging resin 452 into the basin450. In some aspects, the resin application basin 450 may also beconfigured to heat the resin for better impregnation of fibers byreducing the viscosity of the resin. In some aspects, the adjacentunidirectional fibers 415 a-415 f are first exposed or impregnated withresin 452 at first exposure point 423 a and then again at secondexposure point 423 c. The resin is evenly applied to the generallyparallel fibers such that the immediately adjacent unidirectional fibersadhere to one another. In some aspects, the generally parallel extendedunidirectional fibers can be submerged into the resinous material toapply the resin. The resinous material can also be applied in other ways(e.g., spraying, injecting, mechanically spreading) such that the resinis evenly applied across the entire width of the extended unidirectionalfibers such that all the adjacent small-diameter fibers can be adheredto one another. Other comparable aspects of apply or impregnating theadjacent unidirectional fibers are contemplated.

During manufacturing, the unidirectional fibers (e.g., 415 a-415 f) areheld in place mechanically through the use of guides and rollers asillustrated in FIG. 4. When the adjacent unidirectional fibers exit thebasin 450 each of the fibers (e.g., 415 a-415 f) is coated with resin464, 466 as illustrated in window 460. The resin coating might be athicker coating than is desired for the finally manufactured uncuredunidirectional fiber composite kit. In some aspects, the thick resincoating 464, 466 may be reduced at point 424 c by running theresin-coating adjacent unidirectional fibers through rollers 424 a, 424b to squeeze or remove any excess resin that is not desired for thefinished product. Window 470 illustrates an aspect of an exemplary fiber(e.g., 415 a) following a reduction in the resin coating 474, 476.

In some aspects, following the application of the resinous material 452to the generally parallel unidirectional fibers (e.g., 415 a-415 f), themanufacturing process proceeds to adhere the formed unidirectional fiberlayer (see exemplary fiber illustrated in window 470) to a temporaryplastic film 480 used to store the composite system. The plastic filmapplicator 480 can be stored on a roll 430 and the formed unidirectionalfiber layer can be applied to the film in an uncured state using aroller 426, though other methods of applying the layer and film arecontemplated, as well. A cross-section of a single fiber in the formedlayer of adhered unidirectional fibers is illustrated in window 490. Thelayer include the unidirectional fiber (e.g., 415 a) having a lowerresin coating 474 and an upper resin coating 476 that connects oradhered the resin-impregnated fiber to the plastic film applicator 480.In some aspects, after the formed layer of uncured unidirectional fibercomposite extends about additional guides and/or rollers (e.g., 428),the manufactured product can be rolled up and stored on a roll 440 inits uncured state for subsequent processing based on commercial needs oruntil the composite system is ready to be unrolled and applied toreinforce or repair a physical structure.

In some aspects, the systems and methods illustrated by FIG. 4 can bemodified. For example, a direct impregnation methods can be used wherethe resin is directly applied to the unidirectional fibers (e.g., 415a-415 f) between two rollers positioned after roller 420. It is alsocontemplated that the resin may be applied to a polymer or paper tapewhich then transfers the resin to the unidirectional fibers (e.g., 415a-415 f) rather than via resin application basin 450. Otherconfigurations of the rollers illustrated in FIG. 4 that achieve asimilar goal of applying resin to the unidirectional fibers are alsocontemplated.

In some aspects, roller 428 in FIG. 4 can include a protective film tominimize resin from adhering to the roller. It is also contemplated thata roll similar to roll 430 can store a polymer sheet that comes inbetween the resin-impregnated unidirectional fibers after roller 426 andbefore roller 428. The polymer sheet can then be taken off by anotherroller (not shown) after roller 428, but before the resin-impregnatedunidirectional fibers are stored or wound onto roll 440.

In some aspects, it is desirable for several distinct unidirectionalfiber layers to be adhered to each other to form a composite system,similar to what is illustrated and described for FIGS. 2 and 3A-3E andelsewhere herein. Such composite systems may have one or more longerand/or continuous layer(s) formed similar to the process illustrated inFIG. 4. Additional layer(s) can be formed through additionalunidirectional fiber layer(s) being adhered at an angle to the longerlayer(s).

Similar processes are also contemplated where several distinct layersare adhered to each other including unidirectional andnon-unidirectional fiber layers. For example, similar to the processesand system described for FIG. 4, fiber layers already saturated withresinous material, whether unidirectional or non-unidirectional, can beplaced one over another during the process. For example, anon-unidirectional impregnated layer may be placed on top of one or ontop of many unidirectional layers. The process for impregnatingnon-unidirectional fibers is similar to that described for FIG. 4without the use of a temporary plastic film like film 480 or the use ofspools 410. The individual layers are then placed or laid on top of eachother, either in a continuous process through roller or through anon-continuous process of adhering each individual layer one length at atime.

It is contemplated that in some aspects, the composite system can beapplied to a physical structure, such as a pipe or column, using atape-gun type system where a roll of the composite system, asillustrated for example in FIGS. 1A, 3B, and 3C, is placed into thetape-gun like device that is then subsequently used to apply thecomposite system to the structure.

The unidirectional fiber layer of the composite system that is describedherein is fabricated so that the majority of the fibers run in onedirection only. It is unique for some aspects of the composite systemthat for each distinct layer of unidirectional fibers that all of theunidirectional fibers in the layer run in the same direction such thatno secondary fibers run in other directions (e.g., no secondary fibersare used to hold the primary fibers in place), as this could lead to aweakening of the tensile strength of primary fibers. For example, othercomposite system can often include a mechanical connection between thefibers, such as through woven or knitted fabrics or non-woven fabricwhere the fibers are entangled. Other mechanical connections of previoussystems include braided fabrics, twisted or spun fabrics (e.g., aplurality of small-diameter fibers twisted together), stitching,cross-stitching, or weaving. In other aspects, the fibers have beenconnected through a hot melted fiber stitched axially and heated to meltinto the fibers to keep them in place. In contrast, the presentlydescribed composite system with a plurality of unidirectional fibers isheld together or adhered (e.g., bonded) through the stickiness and/orhardening of a resin applied to the plurality of fibers, with nostitching, weaving, or spinning that would create mechanical connections(e.g., frictional connection, other types of mechanical fastening)between the individual fibers.

Resins contemplated for the composite systems described herein can alsoinclude aliphatic or aromatic isocyanate-functionalized compounds. Useof composite materials having aliphatic isocyanate-functionalized resinsthat are contemplated by the present disclosure provide many desirablebenefits over the aromatic resin. For example, use of aliphatic resinsyield lower gas production rate during the curing process. Morespecifically aliphatic isocyanate-functionalized prepolymers oflower-percent isocyanate (NCO) will generate less carbon dioxide thanprepolymers of higher-percent NCO. The formation of voids or bubblescompromises the structural integrity of composites. Effects of andproblems associated with voids are detailed by, for example, SilviaHernández Rueda, “Curing, Defects and Mechanical Performance ofFiber-Reinforced Composites,” Universidad Politécnica De Madrid, EscuelaTécnica Superior de Ingenieros de Caminos, Canales y Puertos (2013)(Doctoral Thesis) (198 pages); Mohamed A. Suhot et al., “The Effect ofVoids on the Flexural Fatigue Performance of Unidirectional Carbon FibreComposites,” 16th Int'l Conf. on Composite Mat'ls (2007) (10 pages);Lenoe, Edward M., “Effect of voids on Mechanical Properties of GraphiteFiber Composites,” prepared by AVCO Corporation and submitted to theU.S. Naval Air Systems Command under contract No. N00019-07-C-0242(1970) (55 pages), the disclosures of which are each incorporated byreference in their entireties. Less carbon dioxide production andproduction rate during curing results in fewer voids in the curedresins, leading to more desirable mechanical properties such as anincreased strength when the aliphatic isocyanate-functionalized resin isused for a composite reinforcement system.

The curing process (sometimes referred to as “wetting”) of aliphaticresins generally takes longer than aromatic resins. The longer curingtime allows gases produced during the curing process to permeate andescape the resin. This results in fewer voids in the cured resins,leading to more desirable mechanical properties, such as strength, whenan aliphatic isocyanate-functionalized resin is used in a compositereinforcement system. In addition to a lower overall production ofcarbon dioxide, any carbon dioxide that is produced by aliphaticisocyanate-functionalized resin has a lower rate of production. When thecarbon dioxide production rate is reduced, carbon dioxide can leave thecuring resin by diffusing out of the system rather than forming bubblesor voids by nucleating. Additionally, the use of an aliphaticisocyanate-functionalized resin in a composite reinforcement system fora physical structure, such as a containment structure, conveyancestructure, or a load-bearing structure, further minimizes laminate rise,which allows for more desirable mechanical properties such as increasedstrength by reducing voids and strain on the plies within the compositematerial or layers of an applied (e.g., wrapped) composite material.Moreover, the longer curing time and permeation of gasses produces lessfoam within the curing resin, thus reducing voids in the cured resin,inhibiting collapse of the voids in the curing and the cured resin, andincreasing strength of the material.

A slower curing process also provides the desirable aspect of allowingfor faster overall application of a composite reinforcement system. Forexample, faster-curing resins such as aromatic isocyanates can lead toproduction of foam on the curing surface, forcing the composite systemaway from the surface to be reinforced, possibly leading to unwantedvoids within the reinforcement system. In order to reduce movement awayfrom the surface, several layers are applied to the surface and thencompressed for a period of time while the resin partially cures beforethe application of more layers to inhibit the effects of the rapidoff-gassing. Layers will have to be applied and compressed in stages toproperly repair and/or reinforce the surface. A desirable aspect ofcomposite reinforcement systems employing aliphaticisocyanate-functionalized resins is that much greater numbers of layerscan be applied to the physical structure that is being reinforced beforethe composite system will need compression, if compression is needed atall. The ability to apply greater numbers of layers to the physicalstructure without stopping results in valuable time savings during arepair or reinforcement of the physical structure, particularly wheremultiple layers of composite reinforcement are needed to meet thedesired post-repair mechanical properties of the physical structure.Moreover, the lower amount of carbon dioxide produced and slowerproduction of carbon dioxide also minimizes or even prevents a drop inthe through-thickness modulus. The through-thickness modulus is ameasure of strain transfer through the thickness of a system.Accordingly, use of aliphatic isocyanates also provides benefits to thecomposite reinforcement system because strain caused by expansion of thestructure (e.g., expansion of a pipe under internal pressure) will betransferred through all layers of the composite reinforcement systemwhich maintains or increases the overall effectiveness of the system.

Composite systems employing aliphatic isocyanate-functionalized resinmaterials can also provide enhanced physical properties of the curedcomposite reinforcement system. For example, the lower porosity of theresin increases permeability during and after curing. Further, use ofaliphatic isocyanate-functionalized resin provides the compositereinforcement system with UV resistance. For example, aliphaticisocyanate-functionalized polyurethane thermoplastics and thermosets aremore UV stable than aromatic isocyanate-functionalized thermoplasticsand thermosets.

Employing an aliphatic resin can desirably allow a user to apply adesired number of layers over a longer period of time than aromaticresins or epoxies. In some embodiments, the layers are applied in aboutten minutes prior to the end of the wrapping procedure or theapplication of compression to the composite reinforcement system. Insome embodiments, the layers are applied for more than about fiveminutes prior to the end of the wrapping procedure or the application ofcompression to the composite reinforcement system. In some embodiments,the layers are applied for more than about ten minutes prior to the endof the wrapping procedure or the application of compression to thecomposite reinforcement system. In some embodiments, the layers areapplied for more than about fifteen minutes prior to the end of thewrapping procedure or the application of compression to the compositereinforcement system. In some embodiments, the layers are applied formore than about twenty minutes prior to the end of the wrappingprocedure or the application of compression to the compositereinforcement system. In some embodiments, the layers are applied formore than about thirty minutes prior to the end of the wrappingprocedure or the application of compression to the compositereinforcement system. In some embodiments, the layers are applied formore than about forty-five minutes prior to the end of the wrappingprocedure or the application of compression to the compositereinforcement system. In some embodiments, the layers are applied formore than about sixty minutes prior to the end of the wrapping procedureor the application of compression to the composite reinforcement system.In some embodiments, the layers are applied for more than about ninetyminutes prior to the end of the wrapping procedure or the application ofcompression to the composite reinforcement system. In some embodiments,the layers are applied for more than about 120 minutes prior to the endof the wrapping procedure or the application of compression to thecomposite reinforcement system. In some embodiments, the layers areapplied for more than about 180 minutes prior to the end of the wrappingprocedure or the application of compression to the compositereinforcement system. In some embodiments, the layers are applied formore than about 240 minutes prior to the end of the wrapping procedureor the application of compression to the composite reinforcement system.

A benefit of a composite reinforcement system using aliphaticisocyanate-functionalized resin is a high-stiffness and high-strengthreinforcement system that minimizes the overall thickness of thereinforced or repaired structure, even for applications where multiplelayers of the composite reinforcement system are applied to the portionof the structure being reinforced. For example, the strength increaseprovides for lower overall thickness (e.g., fewer wraps) needed tosoundly repair a structure. Additionally, a benefit of a compositereinforcement system using aliphatic isocyanate-functionalized resin isthe ability to use thicker overall multi-ply composites withoutencountering issues such as delamination of the plies. For example, thethicker multi-ply composites lower the number of wraps that need to beapplied to soundly repair a structure. Beneficially, fewer requiredwraps also reduces the cost of labor to soundly repair a structure.

In some aspects, additives can be included within an aliphaticisocyanate-functionalized resin, such as an aliphaticisocyanate-functionalized polyurethane resin, to alter at least oneproperty of the resin. For example, additives can include silica, ahindered amine chain extender, or a hydroxy ethyl oxazolidineintermediate. In some embodiments, the altered property is the viscosityof the uncured resin. In some embodiments, the altered property is thethixotropy of the fluid. For example, fumed silica can be added to analiphatic prepolymer mixture to alter or increase the thixotropy of thefluid. The addition of fumed silica increases the viscosity of the resinunder low shear rates and lowers the viscosity at higher shear rates. Insome embodiments, the additive reduces the amount of gas generatedduring the curing process. For example, hindered amine chain extenderreduces the percentage of NCO in the prepolymer which, as stated above,reduces the amount of carbon dioxide generated during curing. In someembodiments, the additive reduces the rate of gas generation duringcuring. For example, hydroxy ethyl oxazolidine intermediate reacts withwater to generate amines and alcohols, diverting the water from reactingwith the isocyanate groups. These amines and alcohols then react withthe isocyanate groups to complete the cure.

In some embodiments of the composite reinforcement systems usingaliphatic isocyanate-functionalized resins, a plurality ofunidirectional fibers (e.g., a carrier) is saturated with the resinprior to storage (e.g., “prepreg” systems). Beneficially, prepregcomposite reinforcement systems employing aliphaticisocyanate-functionalized resins provide many desirable qualities overtypical epoxy resins or aromatic resins. For example, aliphatic resinshave a longer shelf-life than aromatic resins. The longer shelf-lifemakes prepreg aliphatic-resin composite systems more economicallyfeasible, as well as makes repairs more effective because the compositesystem does not lose much flexibility and effectiveness during storage.Additionally, aliphatic resins cure over longer periods of time thanaromatic resins. In some embodiments, it takes several days for thealiphatic resin to cure versus several hours for or aromatic resins tocure. Notably, this longer cure time allows for enhanced properties suchas fewer voids within the cured resin and less mechanical strain createdduring the cure process.

Further, prepreg composite reinforcement systems employing aliphaticisocyanate-functionalized resins allow for more-accurate mixing of thecomponents because the prepreg composite reinforcement systems aremanufactured at a facility where controlled and reliable preparation ofthe systems and components is possible. For example, resins are mixedusing more-accurately measured amounts of each component thanfield-mixed components, providing desired ratios between components ofthe epoxies. These accurate ratios provide for more controlled reactionsduring the cure process and more controlled performance of the compositereinforcement system. Additionally, the mixing and application of theresin to the plurality of unidirectional fibers (e.g., carrier) occursunder more-controlled conditions, such as humidity and temperature, toprovide for more predictable performance at the manufacturing facility.Moreover, prepreg composite reinforcement systems allow for larger lotor batch sizes when mixing the resin. These larger lot sizes provide formore consistent chemistry and mechanical performance between prepregcomposite reinforcement systems than the necessarily smaller-batchfield-applied mixes.

Prepreg composite reinforcement systems employing aliphaticisocyanate-functionalized resins also provide for carrier benefits. Forexample, the thickness of plies of the carrier within a multi-pliedcarrier can be controlled. Additionally, plies of a multi-plied carriermay be individually saturated to provide generally uniform saturation ofa carrier comprising a plurality of unidirectional fibers.

Prepreg composite reinforcement systems employing aliphaticisocyanate-functionalized resins also provide benefits to users. Forexample, users can quickly and effectively apply the compositereinforcement system to a surface without the need to mix chemicals andwait for the carrier to become saturated. Further, the enhancedpliability of the prepreg system when applied to the surface providesfor better coverage and a more-secure fit. Additionally, there is lessrisk of user error when using prepreg systems. The user does not have tomix chemicals, ensure homogeneity of the mixture, apply the chemicals,ensure saturation of the carrier, etc. This leads to increasedmechanical performance and predictability of the composite reinforcementsystem. Further, the ratio of carrier to resin can be optimized toincrease performance of the system, control desired mechanicalproperties, extend shelf life, and reduce cost of the system.

In some embodiments of the composite reinforcement system, it may bedesirable for a carrier to be saturated with resin immediately prior toapplication to the surface to be reinforced (e.g., field-appliedsystems). Beneficially, the use of field-applied composite reinforcementsystems having aliphatic isocyanate-functionalized resins provides forextended shelf life. Additionally, the use of the longer cure period ofthe aliphatic isocyanate-functionalized resins provides for additionaltime to allow the resin to saturate the carrier prior to application.The longer cure time also allows the carrier to be more flexible duringapplication to the surface to be reinforced, yielding a more secureapplication and enhanced mechanical properties of the curedreinforcement.

The composite reinforcement system with uncured resins can be stored orpackaged as part of a repair kit. The kit includes, for example, acomposite reinforcement system including a carrier and an aliphaticresin (e.g., an aliphatic polyurethane resin) sealed in a protectivepackaging such as a moisture-tight pouch. The composite reinforcementsystem can be a prepreg system where the carrier is impregnated with thealiphatic isocyanate-functionalized resin prior to storage.Alternatively, the composite reinforcement system can be a field-appliedsystem. Beneficially, the protective packaging can be used as acontainer to mix or prepare the aliphatic resin and saturate thecarrier. The kit can have a wide range of storage temperatures that willtypically be determined by the type of aliphatic resin used.

According to an alternative embodiment A, a composite system for thereinforcement of physical structures includes a plurality ofunidirectional fibers each having a longitudinal axis and a length. Theplurality of unidirectional fibers are of approximately equal length andarranged with the respective longitudinal axes generally parallel toeach other over a substantial portion of the length of eachunidirectional fiber. The plurality of unidirectional fibers arenon-mechanically connected. A resinous material adheres the plurality ofunidirectional fibers to each other such that each one of the pluralityof unidirectional fiber is adhered to at least one adjacent one of theplurality of unidirectional fibers along a substantial portion of thelength of the adjacent one of the plurality unidirectional fibers.

According to an alternative embodiment B, the composite system ofalternative A further includes that the resinous material is aself-curing epoxy that is initially uncured or initially partiallycured.

According to an alternative embodiment C, the composite system of anyone of alternatives A and B further includes that the unidirectionalfibers are carbon fibers, glass fibers, basalt fibers, aramid fibers,para-aramid synthetic fibers (e.g., Kevlar®, poly-paraphenyleneterephthalamide), metal fibers, or any combination thereof.

According to an alternative embodiment D, the composite system of anyone of alternatives A to C further includes that the carbon fibers arepolyacrylonitrile based, petroleum pitch based, or a combinationthereof.

According to an alternative embodiment E, the composite system of anyone of alternatives A to D further includes that the modulus ofelasticity of the carbon fibers is between the range of about 12 to 30Msi, about 30 to 50 Msi, about 50 to 80 Msi, about 80 to 120 Msi, and/orabout 120 to 150 Msi.

According to an alternative embodiment F, the composite system of anyone of alternatives A to E further includes that the modulus ofelasticity of the glass fibers is between the range of about 5 to 7 Msi,about 7 to 10 Msi, and/or about 10 to 13 Msi.

According to an alternative embodiment G, the composite system of anyone of alternatives A to F further includes that the modulus ofelasticity of the basalt fibers is between the range of about 5 to 8Msi, about 8 to 12 Msi, and/or about 12 to 16 Msi.

According to an alternative embodiment H, the composite system of anyone of alternatives A to G further includes that the resinous materialincludes any one, two, or multicomponent thermosets comprising eitherpolyurethanes, moisture-curable polyurethanes, cationically curableepoxies, dual-stage epoxies, polyamides, polyureas, polyimides,polyoxazolidones, polycarbonates, polyethers, polysiloxanes,polyolefins, polybutadienes, silanes, vinylesters, polythiols,polyamines, polyols, polyisocyanates, polyisobutylenes, or any viablecombination thereof.

According to an alternative embodiment I, the composite system of anyone of alternatives A to H further includes that the resinous materialincludes a polyurethane material (such as a moisture curablepolyurethane material) having an aliphatic prepolymer chemicallyconfigured to activate and harden after removal from a generally inertenvironment and exposure to moisture, such as moisture in air.Alternatively, the composite system of any one of alternatives A to Hfurther includes that the resinous material is an aliphaticisocyanate-functionalized resin.

According to an alternative embodiment J, the composite system of anyone of alternatives A to I further includes that the aliphaticprepolymer is an aliphatic isocyanate prepolymer.

According to an alternative embodiment K, the composite system of anyone of alternatives A to J further includes that the resinous materialis a moisture-curable urethane resin.

According to an alternative embodiment L, the composite system of anyone of alternatives A to K further includes that the unidirectionalfibers are preimpregnated with the moisture-curable urethane resin andthe composite system being stored in an uncured or partially cured statein a moisture-tight enclosure.

According to an alternative embodiment M, the composite system of anyone of alternatives A to L further includes that the ratio ofunidirectional fibers to resinous material is between the range byvolume of about a 60:40 to a 50:50 ratio, about a 50:50 to a 40:60ratio, about a 40:60 to a 30:70 ratio, about a 30:70 to a 20:80 ratio,about a 40:60 to 80:20 ratio, about a 40:60 to 75:25 ratio, and/or abouta 60:40 to a 20:80 ratio.

According to an alternative embodiment N, the composite system of anyone of alternatives A to L further includes that the ratio ofunidirectional fibers to resinous material is between the ranges ofabout a 80:20 to a 20:80 ratio by volume.

According to an alternative embodiment O, the composite system of anyone of alternatives A to L further includes that the number ofunidirectional fibers per unit width, as measured generallyperpendicular to the longitudinal axes of the adjacent unidirectionalfibers, is between the range of about 100 to 200 fibers per inch, about200 to 500 fibers per inch, about 500 to 1000 fibers per inch, about1000 to 2000 fibers per inch, about 2000 to 4000 fibers per inch, and/orabout 4000 to 8500 fibers per inch.

According to an alternative embodiment P, the composite system of anyone of alternatives A to O further includes that the overall width ofthe composite system, as measured generally perpendicular to thelongitudinal axes of the adjacent plurality of unidirectional fibers, isbetween the range of about 0.5 to 24 inches (including subranges withinthis range).

According to an alternative embodiment Q, the composite system of anyone of alternatives A to P further includes that the resinous materialis initially uncured or initially partially cured and that the resinousmaterial is curable by heat curing, moisture curing, ultraviolet lightexposure, and/or electron beam curing.

According to an alternative embodiment R, the composite system of anyone of alternatives A to Q further includes that the resinous materialis heat curable at temperatures exceeding about 400 degrees F.

According to an alternative embodiment S, the composite system of anyone of alternatives A to Q further includes that the resinous materialis curable at temperatures below about 40 degrees F.

According to an alternative embodiment T, the composite system of anyone of alternatives A to S further includes that the adjacent pluralityof unidirectional fibers form a unidirectional fiber layer. The resinousmaterial is configured to adhere and/or bond the unidirectional fiberlayer to concrete, wood, steel, titanium, brass, bronze, copper,aluminum, or any combinations thereof.

According to an alternative embodiment U, the composite system of anyone of alternatives A to T further includes that the adjacent pluralityof unidirectional fibers form a unidirectional fiber layer, and that adisposable plastic film applicator has a width greater than or equal toan overall width of the unidirectional fiber layer as measured generallyperpendicular to the longitudinal axes of the plurality ofunidirectional fibers. The disposable plastic film applicator furtherhas a length approximately equal to the length of the plurality ofunidirectional fibers. The resinous material temporarily adheres theunidirectional fiber layer to the disposable plastic film applicator.

According to an alternative embodiment V, the composite system of anyone of alternatives A to U further includes a central core upon whichthe disposable plastic film applicator with the resinous materialadhering the unidirectional fiber layer thereon is wound.

According to an alternative embodiment W, the composite system of anyone of alternatives A to V further includes that the plurality ofunidirectional fibers include a combination of carbon fibers andfiberglass.

According to an alternative embodiment X, the composite system of anyone of alternatives A to W further includes that in response to theresinous material being fully cured, the composite system of theresinous material and the plurality of unidirectional fibers has atensile strength along the longitudinal axes in the range of one or moreof about 30 to 50 ksi, about 50 to 100 ksi, about 100 to 200 ksi, about200 to 400 ksi, and/or about 400 to 600 ksi.

According to an alternative embodiment Y, the composite system of anyone of alternatives A to X further includes that in response to theresinous material being fully cured, the composite system including theresinous material and the plurality of unidirectional fibers has a ShoreD hardness value in the range of one or more of about 60 to 70, about 70to 80, about 80 to 90, and/or about 90 to 100.

According to an alternative embodiment Z, a repair kit including thecomposite system of any one of alternatives A to Y further includes amoisture tight enclosure configured to store the composite system.

According to an alternative embodiment AA, a structural reinforcementassembly of any one of alternatives A to Z further includes that thecomposite system is configured to be applied to the physical structure.The physical structure being reinforced includes one of a pipe, a tank,a concrete beam, a concrete slab, a concrete column, a concrete square,a steel column, a steel beam, a wall, or a floor slab.

According to an alternative embodiment AB, the structural reinforcementsystem of any one of alternatives A to AA further includes that thecomposite system is wrapped around a pipeline assembly in one or moreoverlapping layers.

According to an alternative embodiment AC, the structural reinforcementsystem of any one of alternatives A to AB further includes that thecomposite system is wrapped around a pipeline assembly in one or moreoverlapping layers. The wrapped pipeline assembly includes the compositesystem increasing the outer diameter of the pipeline assembly by lessthan about 0.05 inches, by between about 0.05 to 0.25 inches, by betweenabout 0.25 to 0.5 inches, by between about 0.5 to 0.75 inches, bybetween about 0.75 to 1 inch, by between about 1 to 2 inches, and/or bybetween about 2 to 4 inches.

According to an alternative embodiment AD, the structural reinforcementsystem of any one of alternatives A to AC further includes that thecomposite system is applied to an inner surface extending about thecircumference on the interior side of a pipeline assembly in one or moreoverlapping layers. The interior of the pipeline assembly including thecomposite system decreasing the inner diameter of the pipeline assemblyby less than about 0.05 inches, by between about 0.05 to 0.25 inches, bybetween about 0.25 to 0.5 inches, by between about 0.5 to 0.75 inches,by between about 0.75 to 1 inch, by between about 1 to 2 inches, and/orby between about 2 to 4 inches.

According to an alternative embodiment AE, the structural reinforcementsystem of any one of alternatives A to AD further includes that thecomposite system is applied in one or more layers to an outer surface ofa concrete column having a circular cross-section, a squarecross-section, a rectangular cross-section, or any polygonalcress-sectional shape. The application of the composite system to theconcrete column increases the respective outer diameter, outercross-sectional length, or the outer cross-sectional width of thecross-section of the concrete column by less than about 0.1 inches, bybetween about 0.1 to 0.5 inches, by between about 0.5 to 1 inch, bybetween about 1 to 2 inches, and/or by between about 2 to 4 inches.

According to an alternative embodiment AF, the structural reinforcementsystem of any one of alternatives A to AE further includes that thecomposite system is applied in one or more layers to a steel web surfaceof a steel flange column. The steel web has a thickness. The applicationof the composite system to steel web surface increases the overallthickness of the web by less than 1.25 times the thickness of the steelweb, by between about 1.25 to 1.5 times the thickness of the steel web,and/or by between about 1.5 to 2 times the thickness of the steel web.

According to an alternative embodiment AG, the structural reinforcementsystem of any one of alternatives A to AF further includes that thecomposite system is applied in one or more layers to a steel flangesurface of a steel flange column. The steel flange has a thickness. Theapplication of the composite system to the steel flange surfaceincreases the overall thickness of the flange by less than 1.25 timesthe thickness of the steel flange, by between about 1.25 to 1.5 timesthe thickness of the steel flange, and/or by between about 1.5 to 2times the thickness of the steel flange.

According to an alternative embodiment AH, the structural reinforcementsystem of any one of alternatives A to AG further includes the compositesystem being applied in one or more layers around a hollow steel tubecolumn having a steel tube wall thickness. The application of thecomposite system to the hollow steel tube column increases an overallthickness of the tube wall by less than 1.25 times the thickness of thesteel tube wall, by between about 1.25 to 1.5 times the thickness of thesteel tube wall, and/or by between about 1.5 to 2 times the thickness ofthe steel tube wall.

According to an alternative embodiment AI, a method of manufacturing acomposite system for the reinforcement of physical structures isdescribed. The composite system includes a plurality of unidirectionalfibers and a resinous material adhering the plurality of unidirectionalfibers to each other. The method comprises providing a first supply rollincluding a disposable applicator film. A first plurality of individualsupply spools of first unidirectional fibers is provided. Eachunidirectional fiber has a first longitudinal axis. The first individualsupply spools of first unidirectional fibers are arranged adjacent toeach other. The disposable applicator film from the first supply roll isextended to a second collector roll. The first unidirectional fibersfrom the first individual supply spools are extended such that the firstunidirectional fibers are parallel to each other and are disposed aboveor below the disposable applicator film. During the extending of thedisposable applicator film and the extending of the first unidirectionalfibers, the resinous material is applied to the first unidirectionalfibers along the width of each of the first unidirectional fibers suchthat the resinous material is generally evenly applied and impregnatesthe first unidirectional fibers such that the first unidirectionalfibers adhere to each other. The resin impregnated first unidirectionalfibers are adhered to and/or placed on the disposable applicator film.The adhered first unidirectional fibers are generally parallel to eachother. Each of the first unidirectional fibers are adhered to at leastone adjacent one of the first unidirectional fibers along a substantialportion of the adjacently adhered fibers such that the firstunidirectional fibers are non-mechanically bound to each other.

According to an alternative embodiment AJ, the method of alternative AIfurther includes providing a second plurality of individual supplyspools of second unidirectional fibers. Each of the secondunidirectional fibers has a second longitudinal axis. The secondunidirectional fibers are extended from the second individual supplyspools such that the second longitudinal axes are generally parallel toeach other. The second unidirectional fibers are further disposed aboveand/or below the extended first unidirectional fibers. The secondlongitudinal axes of the extended second unidirectional fibers traverseabove and/or below the extended first unidirectional fibers at a firstangle to the first longitudinal axes. During the extending of the secondunidirectional fibers, resinous material is applied to the secondunidirectional fibers along the width of each of the secondunidirectional fibers such that the resinous material is generallyevenly applied and impregnates the second unidirectional fibers suchthat the second unidirectional fibers adhere to each other. The resinimpregnated second unidirectional fibers are pressed to the resinimpregnated first unidirectional fibers. The adhered secondunidirectional fibers are generally parallel to each other. Each of thesecond unidirectional fibers are adhered to at least one adjacent one ofthe second unidirectional fibers along a substantial portion of theadjacently adhered fibers such that the second unidirectional fibers arenon-mechanically bound to each other.

According to an alternative embodiment AK, the method of any one ofalternatives AI to AJ further includes that after the pressing of thesecond unidirectional fibers to the first unidirectional fibers, thefirst unidirectional fibers define a first plane and the secondunidirectional fibers define a second plane such that the first plane isgenerally parallel to the second plane and the first longitudinal axesof the first unidirectional fibers are skew to the second longitudinalaxes of the second unidirectional fibers. The smallest angle between anyone of the first longitudinal axes of the first unidirectional fibersand any one of the second longitudinal axes of the second unidirectionalfibers being in between the range of about zero to 15 degrees, about 15to 30 degrees, about 30 to 45 degrees, about 45 to 60 degrees, about 60to 75 degrees, and/or about 75 to 90 degrees (or any combinations ofthese ranges).

According to an alternative embodiment AL, the method of any one ofalternatives AI to AK further includes that after the pressing of thesecond unidirectional fibers to the first unidirectional fibers, thefirst unidirectional fibers define a first plane and the secondunidirectional fibers define a second plane such that the first plane isgenerally parallel to the second plane and the first longitudinal axesof the first unidirectional fibers are skew to the second longitudinalaxes of the second unidirectional fibers, the smallest angle between anyone of the first longitudinal axes of the first unidirectional fibersand any one of the second longitudinal axes of the second unidirectionalfibers being about 15 degrees, about 30 degrees, about 45 degrees, about60 degrees, about 75 degrees, and/or about 90 degrees.

According to an alternative embodiment AM, the method of any one ofalternatives AI to AL further includes that the first unidirectionalfibers each have a first diameter and the second unidirectional fiberseach have a second diameter. The first diameter is different from thesecond diameter.

According to an alternative embodiment AN, the method of any one ofalternatives AI to AM further includes providing a third plurality ofindividual supply spools of third unidirectional fibers. Each of thethird unidirectional fiber has a third longitudinal axis. The thirdunidirectional fibers extend from the third individual supply spoolssuch that the third longitudinal axes of the third unidirectional fibersare generally parallel to each other. The third unidirectional fibersare disposed above or below the extended second unidirectional fiberssuch that the second unidirectional fibers are disposed between thefirst unidirectional fibers and the third unidirectional fibers. Thethird longitudinal axes of the third unidirectional fibers traverseabove or below the extended second unidirectional fibers at a secondangle to the first longitudinal axes and a third angle to the secondlongitudinal axes. The second angle is different than the third angle.During the extending of the third unidirectional fibers, resinousmaterial is applied to the third unidirectional fibers along the widthof each of the third unidirectional fibers such that the resinousmaterial is generally evenly applied and impregnates the thirdunidirectional fibers such that the third unidirectional fibers adhereto each other. The resin impregnated third unidirectional fibers ispressed to the resin impregnated second unidirectional fibers. The thirdunidirectional fibers are generally parallel to each other. Each of thethird unidirectional fibers are adhered to at least one adjacent one ofthe third unidirectional fibers along a substantial portion of theadjacently adhered fibers such that the third unidirectional fibers arenon-mechanically bound to each other.

According to an alternative embodiment AO, the method of any one ofalternatives AI to AN further includes that after the pressing of thethird unidirectional fibers to the second unidirectional fibers, thethird unidirectional fibers define a third plane and the secondunidirectional fibers define a second plane such that the third plane isgenerally parallel to the second plane and the third longitudinal axesof the third unidirectional fibers are skew to the second longitudinalaxes of the second unidirectional fibers. The smallest angle between anyone of the second longitudinal axes of the second unidirectional fibersand any one of the third longitudinal axes of the third unidirectionalfibers being in between the range of about zero to 15 degrees, about 15to 30 degrees, about 30 to 45 degrees, about 45 to 60 degrees, about 60to 75 degrees, and/or about 75 to 90 degrees (or any combinations ofthese ranges).

According to an alternative embodiment AP, the method of any one ofalternatives AI to AO further includes that after the pressing of thethird unidirectional fibers to the second unidirectional fibers, thethird unidirectional fibers define a third plane and the secondunidirectional fibers define a second plane such that the third plane isgenerally parallel to the second plane and the third longitudinal axesof the third unidirectional fibers are skew to the second longitudinalaxes of the second unidirectional fibers. The angle between any one ofthe second longitudinal axes of the second unidirectional fibers and anyone of the third longitudinal axes of the third unidirectional fibersare about 15 degrees, about 30 degrees, about 45 degrees, about 60degrees, about 75 degrees, and/or about 90 degrees.

According to an alternative embodiment AQ, the method of any one ofalternatives AI to AP further includes that the first unidirectionalfibers each have a first diameter, the second unidirectional fibers eachhave a second diameter, and the third unidirectional fibers each havinga third diameter. At least one of the first diameter, the seconddiameter, and the third diameter are a different than the other twodiameters.

According to an alternative embodiment AR, the method of any one ofalternatives AI to AQ further includes providing a third plurality ofindividual supply spools of third unidirectional fibers. Each of thethird unidirectional fiber have a third longitudinal axis. The thirdunidirectional fibers extend from each of the third individual supplyspools such that the third longitudinal axes of the third unidirectionalfibers are generally parallel to each other. The third unidirectionalfibers are disposed above or below the extended second unidirectionalfibers such that the second unidirectional fibers are disposed betweenthe first unidirectional fibers and the third unidirectional fibers. Thethird longitudinal axes of the third unidirectional fibers traverseabove or below the extended second unidirectional fibers generallyparallel to the first longitudinal axes. During the extending of thethird unidirectional fibers, applying resinous material to the thirdunidirectional fibers along the width of each of the thirdunidirectional fibers such that the resinous material is generallyevenly applied and impregnates the third unidirectional fibers such thatthe third unidirectional fibers adhere to each other. The resinimpregnated third unidirectional fibers is pressed to the resinimpregnated second unidirectional fibers. The third unidirectionalfibers are generally parallel to each other. Each of the thirdunidirectional fibers are adhered to at least one adjacent one of thethird unidirectional fibers along a substantial portion of theadjacently adhered fibers such that the third unidirectional fibers arenon-mechanically bound to each other.

According to an alternative embodiment AS, a composite system for thereinforcement of physical structures includes a plurality of firstunidirectional fibers each having a first longitudinal axis and a firstlength. The plurality of first unidirectional fibers are ofapproximately equal length and arranged with the respective firstlongitudinal axes generally parallel to each other over a substantialportion of the first length of each first unidirectional fiber. Aplurality of second unidirectional fibers each have a secondlongitudinal axis and a second length. The plurality of secondunidirectional fibers are of approximately equal length and arrangedwith the respective second longitudinal axes generally parallel to eachother over a substantial portion of the second length of the secondunidirectional fibers. The second length is less than the first length.A resinous material adheres the plurality of first unidirectional fibersto each other such that each of the plurality of first unidirectionalfibers is adhered to at least one adjacent one of the plurality of firstunidirectional fibers along a substantial portion of the first length ofthe adjacent first unidirectional fibers thereby forming a firstunidirectional fiber layer of generally non-mechanically connected firstunidirectional fibers to define a first plane. The resinous materialfurther adheres the plurality of second unidirectional fibers to eachother such that each of the plurality of second unidirectional fibers isadhered to at least one adjacent one of the plurality of secondunidirectional fibers along a substantial portion of the second lengthof the adjacent second unidirectional fibers thereby forming a secondunidirectional fiber layer of generally non-mechanically connectedsecond unidirectional fibers to define a second plane. The plurality ofsecond unidirectional fibers are oriented such that any one of thesecond longitudinal axes in the second plane is skew to any one of thefirst longitudinal axes in the first plane. The first unidirectionalfiber layer and the second unidirectional fiber layer arenon-mechanically connected.

According to an alternative embodiment AT, the composite system ofalternative AS further includes a plurality of third unidirectionalfibers each having a third longitudinal axis and a third length. Theplurality of third unidirectional fibers are of approximately equallength and arranged with the respective third longitudinal axesgenerally parallel to each other over a substantial portion of the thirdlength of the third unidirectional fibers. The resinous material furtheradheres the plurality of third unidirectional fibers to each other suchthat each of the plurality of third unidirectional fibers is adhered toat least one adjacent one of the plurality of third unidirectionalfibers along a substantial portion of the third length of the adjacentthird unidirectional fibers thereby forming the third unidirectionalfiber layer defining a third plane. The resinous material furtheradheres the first unidirectional fiber layer to the secondunidirectional fiber layer and the second unidirectional fiber layer tothe third unidirectional fiber layer. The plurality of thirdunidirectional fibers are oriented such that any one of the thirdlongitudinal axes in the third plane is skew to any one of the firstlongitudinal axes in the first plane and further skew to any one of thesecond longitudinal axes in the first plane. The third unidirectionalfiber layer and the second unidirectional fiber layer arenon-mechanically connected.

According to an alternative embodiment AU, the composite system of anyone of alternatives AS to AT further includes that the smallest anglebetween any one of the second longitudinal axes of the secondunidirectional fibers and the third longitudinal axes of the thirdunidirectional fibers is between the range of about zero to 15 degrees,about 15 to 30 degrees, about 30 to 45 degrees, about 45 to 60 degrees,about 60 to 75 degrees, and/or about 75 to 90 degrees (or anycombinations of these ranges).

According to an alternative embodiment AV, the composite system of anyone of alternatives AS to AU further includes that the smallest anglebetween any one of the second longitudinal axes of the secondunidirectional fibers and any one of the third longitudinal axes of thethird unidirectional fibers is about 15 degrees, about 30 degrees, about45 degrees, about 60 degrees, about 75 degrees, and/or about 90 degrees.

According to an alternative embodiment AW, the composite system of anyone of alternatives AS to AV further includes that the firstunidirectional fibers each have a first diameter, the secondunidirectional fibers each have a second diameter, and the thirdunidirectional fibers each having a third diameter. At least one of thefirst diameter, the second diameter, and the third diameter aredifferent than the other two diameters.

According to an alternative embodiment AX, the composite system of anyone of alternatives AS to AW further includes a plurality of thirdunidirectional fibers each having a third longitudinal axis and a thirdlength. The plurality of third unidirectional fibers are approximatelyequal in length and arranged with the third longitudinal axes generallyparallel to each other over a substantial portion of the third length ofthe third unidirectional fibers. The resinous material further adheresthe plurality of third unidirectional fibers to each other such thateach of the plurality of third unidirectional fibers is adhered to atleast one adjacent one of the plurality of third unidirectional fibersalong a substantial portion of the length of the adjacent thirdunidirectional fibers thereby forming the third unidirectional fiberlayer defining a third plane. The resinous material further adheres thefirst unidirectional fiber layer to the second unidirectional fiberlayer and the second unidirectional fiber layer to the thirdunidirectional fiber layer. The plurality of third unidirectional fibersare oriented such that any one of the third longitudinal axes in thethird plane is skew to any one of the first longitudinal axes in thefirst plane and further skew to any one of the second longitudinal axesin the second plane. The smallest angle between any one of the thirdlongitudinal axes and any one of the first longitudinal axes is aboutzero degrees. The third unidirectional fiber layer and the secondunidirectional fiber layer are non-mechanically connected.

According to an alternative embodiment AY, the composite system of anyone of alternatives AS to AX further includes a disposable film having awidth greater than an overall width of the adjacent plurality of firstunidirectional fibers. The width is measured generally perpendicular tothe longitudinal axes of the plurality of first unidirectional fibers.The disposable film further has a length approximately equal to thelength of the plurality of first unidirectional fibers. The resinousmaterial temporarily adheres the plurality of first unidirectionalfibers, the plurality of second unidirectional fibers, or the pluralityof third unidirectional to the disposable film.

According to an alternative embodiment AZ, the composite system of anyone of alternatives AS to AY further includes that the resinous materialis a self-curing epoxy that is initially partially cured or uncured.

According to an alternative embodiment BA, the composite system of anyone of alternatives AS to AZ further includes that the firstunidirectional fibers, the second unidirectional fibers, and/or thethird unidirectional fibers are carbon fibers, fiberglass, basaltfibers, aramid fibers, para-aramid synthetic fibers (e.g., Kevlar®,poly-paraphenylene terephthalamide), metal fibers, or any combinationthereof.

According to an alternative embodiment BB, the composite system of anyone of alternatives AS to BA further includes that the carbon fibers arepolyacrylonitrile based, petroleum pitch based, or a combinationthereof.

According to an alternative embodiment BC, the composite system of anyone of alternatives AS to BB further includes that the resinous materialincludes polyurethanes, polyamides, polyureas, polyimides,polyoxazolidones, polycarbonates, polyethers, polysiloxanes,polyolefins, polybutadienes, silanes, vinylesters, polythiols,polyamines, polyols, polyisocyanates, polyisobutylenes, cationics, orany viable combination thereof.

According to an alternative embodiment BD, the composite system of anyone of alternatives AS to BC further includes that the resinous materialis a moisture-curable urethane resin.

According to an alternative embodiment BE, the composite system of anyone of alternatives AS to BD further includes that the firstunidirectional fibers, the second unidirectional fibers, and/or thethird unidirectional fibers are impregnated with the moisture-curableurethane resin. The composite system is stored in an uncured state or apartially cured state in a moisture tight enclosure.

According to an alternative embodiment BF, the composite system of anyone of alternatives AS to BE further includes that the ratio ofunidirectional fibers to resinous material is between the range byvolume of about a 60:40 to a 50:50 ratio, about a 50:50 to a 40:60ratio, about a 40:60 to a 30:70 ratio, about a 30:70 to a 20:80 ratio,about a 40:60 to 80:20 ratio, about a 40:60 to 75:25 ratio, and/or abouta 60:40 to a 20:80 ratio.

According to an alternative embodiment BG, the composite system of anyone of alternatives AS to BF further includes that the number ofunidirectional fibers per unit width as measured generally perpendicularto the longitudinal axes of the adjacent unidirectional fibers isbetween the range of about 100 to 200 fibers per inch, about 200 to 500fibers per inch, about 500 to 1000 fibers per inch, about 1000 to 2000fibers per inch, about 2000 to 4000 fibers per inch, and/or about 4000to 8500 fibers per inch.

According to an alternative embodiment BH, the composite system of anyone of alternatives AS to BG further includes that the overall width ofthe composite system as measured generally perpendicular to the firstlongitudinal axes is between the range of about 0.5 inches to 24 inches(including subranges thereof).

According to an alternative embodiment BI, the composite system of anyone of alternatives AS to BH further includes that the resinous materialis initially uncured or initially partially cured. The resinous materialis curable by heat curing, moisture curing, ultraviolet light exposure,and/or electron beam curing.

According to an alternative embodiment BJ, the composite system of anyone of alternatives AS to BI further includes that the resinous materialis heat curable at temperatures exceeding about 400 degrees F.

According to an alternative embodiment BK, the composite system of anyone of alternatives AS to BJ further includes that wherein the resinousmaterial is curable at temperatures below about 40 degrees F.

According to an alternative embodiment BL, the composite system of anyone of alternatives AS to BK further includes that the resinous materialis configured to adhere or bond at least one of the plurality ofunidirectional fiber layers to concrete, wood, steel, titanium, brass,bronze, copper, aluminum, or any combination thereof.

According to an alternative embodiment BM, the composite system of anyone of alternatives AS to BL further includes a central core upon whichthe disposable film with the resinous material adhering the plurality ofunidirectional fibers thereon is wound.

According to an alternative embodiment BN, the composite system of anyone of alternatives AS to BM further includes that the plurality offirst unidirectional fibers, second unidirectional fibers, and/or thirdunidirectional fibers includes a combination of carbon fibers andfiberglass.

According to an alternative embodiment BO, a kit including the compositesystem of any one of alternatives AS to BN further includes that the kitfurther comprising a moisture tight enclosure configured to store thecomposite system.

According to an alternative embodiment BP, a composite system for thereinforcement of physical structures includes a first unidirectionalfiber layer including a plurality of non-mechanically connected firstunidirectional fibers each having a first longitudinal axis and a firstlength. The plurality of first unidirectional fibers are ofapproximately equal length and arranged with the respective firstlongitudinal axes generally parallel to each other over a substantiallythe entire first length of each first unidirectional fiber. Theplurality of first unidirectional fibers includes electrically and/orheat conductive materials. The plurality of first unidirectional fibersare adhered to each other by a resinous material such that each of theplurality of first unidirectional fibers is adhered to at least oneadjacent one of the plurality of first unidirectional fibers alongsubstantially the entire first length of an adjacent firstunidirectional fiber. A second insulating fiber layer is adhered to thefirst unidirectional fiber layer by the resinous material and/or anotherresinous material. The second insulating layer separates theelectrically and/or heat conductive material(s) in the firstunidirectional fiber layer from direct contact with an electricallyand/or heat conductive physical structure being reinforced by thecomposite system.

According to an alternative embodiment BR, the composite system ofalternative BP further includes that the plurality of firstunidirectional fibers are non-metallic fibers, metal fibers, carbonfibers, or any combinations thereof; and/or wherein the second insultingfiber layer includes glass fibers, basalt fibers, aramid fibers,para-aramid synthetic fibers (e.g., Kevlar®, poly-paraphenyleneterephthalamide), or any combinations thereof.

According to an alternative embodiment BS, the composite system of anyone of alternatives BP to BR further includes that the carbon fibers arepolyacrylonitrile based, petroleum pitch based, or any combinationsthereof.

According to an alternative embodiment BT, the composite system of anyone of alternatives BP to BS further includes that the second insulatingfiber layer includes unidirectional fibers, woven fibers, non-wovenfibers, mat fibers, or any combinations thereof.

According to an alternative embodiment BU, the composite system of anyone of alternatives BP to BT further includes a third layer. The thirdlayer is separated from the first unidirectional fiber layer by thesecond insulating fiber layer. The third layer is in contact with thesecond insulating fiber layer. The third layer is a primer, a coating, agel, an insulator, or any combinations thereof. The third layer isadapted to be applied directly to the electrical and/or heat conductivephysical structure.

According to an alternative embodiment BV, the composite system of anyone of alternatives BP to BU further includes that the resinous materialis a moisture-cured resin.

According to an alternative embodiment BW, the composite system of anyone of alternatives BP to BV further includes that the composite systemis stored in an uncured or partially cured state in a moisture-tightand/or air-tight enclosure.

According to an alternative embodiment BX, the composite system of anyone of alternatives BP to BW further includes that the resinous materialis a urethane resin.

According to an alternative embodiment BY, a kit for forming thecomposite system of any one of alternatives BP to BX includes the firstunidirectional fiber layer, the second insulating fiber layer, the thirdlayer, the resinous material(s), or any combinations thereof.

According to an alternative embodiment BZ, the composite system,methods, or kits of any of the preceding alternatives A to BY includethat the resinous material is a moisture-cured resin.

According to an alternative embodiment CA, the composite system,methods, or kits of any of the preceding alternatives A to BZ includethat the composite system is stored in an uncured or partially curedstate in a moisture-tight and/or air-tight enclosure.

According to an alternative embodiment CB, the composite system,methods, or kits of any of the preceding alternatives A to CA includethat the resinous material is a urethane resin

While this disclosure is susceptible to various modifications andalternative forms, specific embodiments have been shown by way ofexample in the drawings and will be described in detail herein. Itshould be understood, however, that the invention is not intended to belimited to the particular forms disclosed. Rather, the invention is tocover all modifications, equivalents, and alternatives falling withinthe spirit and scope of the disclosure.

What is claimed is:
 1. A repair kit for reinforcement of a physicalstructure, comprising: a pouch defining a moisture-tight enclosure; anda plurality of non-mechanically connected unidirectional carbon fiberslocated within the enclosure, each carbon fiber of the plurality ofnon-mechanically connected unidirectional carbon fibers beingpreimpregnated and adhered to an adjacent unidirectional carbon fiber ofthe plurality of non-mechanically connected unidirectional carbon fibersby a resinous material comprising a moisture-curable prepolymer, theresinous material being in a partially-cured state within themoisture-tight enclosure, the modulus of elasticity of theunidirectional carbon fibers being in a range of about 12 Msi to 150Msi, wherein the resinous material, after removal from the pouch, isconfigured to transition to a fully-cured and hardened state on thephysical structure in response to exposure to moisture.
 2. The repairkit of claim 1, wherein the resinous material includes a polyurethanematerial.
 3. The repair kit of claim 1, wherein the moisture-curableprepolymer includes an isocyanate-functionalized prepolymer.
 4. Therepair kit of claim 3, wherein the isocyanate-functionalized prepolymeris an aliphatic isocyanate-functionalized polyurethane prepolymer, analiphatic isocyanate-functionalized polyurea prepolymer, an aliphaticisocyanate-functionalized polyurea-polyurethane hybrid prepolymer, or analiphatic isocyanate-functionalized polyamide prepolymer.
 5. The repairkit of claim 1, wherein a ratio of fibers to resinous material isbetween a range of about a 40:60 to a 80:20 by volume.
 6. The repair kitof claim 1, wherein the plurality of non-mechanically connectedunidirectional carbon fibers and the resinous material are provided inthe pouch as part of a roll.
 7. The repair kit of claim 6, furtherincluding a disposable film attached to the plurality ofnon-mechanically connected unidirectional carbon fibers via thepartially-cured resinous material to keep adjacent unidirectional carbonfiber layers within the roll from attaching to each other.
 8. The repairkit of claim 1, wherein the physical structure is a concrete structureor a metal structure.
 9. The repair kit of claim 1, wherein themoisture-curable prepolymer is an aliphatic moisture-curable prepolymer.10. The repair kit of claim 1, wherein the plurality of non-mechanicallyconnected unidirectional carbon fibers are non-mechanically connected bythe resinous material forming a matrix that bonds the unidirectionalcarbon fibers together such that there is no other connection betweenthe unidirectional carbon fibers.
 11. A repair kit for the reinforcementof a physical structure, comprising: a sealed package defining amoisture-tight enclosure; a first unidirectional carbon fiber layerincluding a plurality of first non-mechanically connected unidirectionalcarbon fibers located within the moisture-tight enclosure, the modulusof elasticity of the first unidirectional carbon fibers being in therange of about 12 Msi to 150 Msi; a second fiber layer including aplurality of second fibers located within the moisture-tight enclosure,the second fiber layer overlaying the first fiber layer; a resinousmaterial preimpregnating and adhering the plurality of firstnon-mechanically connected unidirectional carbon fibers to each othersuch that each of the plurality of first non-mechanically connectedunidirectional carbon fibers is adhered to at least one adjacent one ofthe plurality of first non-mechanically connected unidirectional carbonfibers, the resinous material further preimpregnating the plurality ofsecond fibers, the resinous material adhering the first unidirectionalcarbon fiber layer to the second fiber layer, wherein the resinousmaterial comprises a moisture-curable prepolymer that is stored in apartially-cured state within the moisture-tight enclosure, themoisture-curable prepolymer being configured to be fully-cured inresponse to the resinous material being exposed to moisture while thefirst and second fibers are adhered to the physical structure afterremoval from the sealed package.
 12. The repair kit of claim 11, whereinthe resinous material includes a polyurethane material.
 13. The repairkit of claim 11, further comprising a disposable film temporarilyadhered to one of the first unidirectional carbon fiber layer or thesecond fiber layer while in the package.
 14. The repair kit of claim 11,wherein the resinous material is configured to adhere the firstunidirectional carbon fiber layer and the second fiber layer toconcrete, wood, steel, titanium, brass, bronze, copper, aluminum, or anycombination thereof.
 15. The repair kit of claim 11, wherein theplurality of second fibers is unidirectional fibers, the resinousmaterial adhering the plurality of second fibers to each other such thateach of the plurality of second fibers is adhered to at least oneadjacent one of the plurality of second fibers.
 16. The repair kit ofclaim 11, wherein the moisture-curable prepolymer is anisocyanate-functionalized prepolymer.
 17. The repair kit of claim 16,wherein the isocyanate-functionalized prepolymer is an aliphaticisocyanate-functionalized polyurethane prepolymer, an aliphaticisocyanate-functionalized polyurea prepolymer, an aliphaticisocyanate-functionalized polyurea-polyurethane hybrid prepolymer, or analiphatic isocyanate-functionalized polyamide prepolymer.
 18. The repairkit of claim 11, wherein the second fiber layer includes carbon fibers.19. The repair kit of claim 11, wherein the moisture-curable prepolymeris an aliphatic moisture-curable prepolymer.
 20. A repair kit forreinforcement of a physical structure, comprising: a pouch defining amoisture-tight enclosure; and a plurality of non-mechanically connectedunidirectional fibers located within the moisture-tight enclosure, theplurality of non-mechanically connected unidirectional fibers beingpreimpregnated with a resinous material comprising an aliphaticmoisture-curable polyurethane, the resinous material being in apartially-cured state within the moisture-tight enclosure, wherein theresinous material, after removal from the pouch, is configured totransition to a fully-cured and hardened polyurethane material inresponse to exposure to moisture while being adhered to the physicalstructure.
 21. The repair kit of claim 20, wherein each of thenon-mechanically connected unidirectional fibers are adhered to anadjacent unidirectional fiber by the resinous material.
 22. The repairkit of claim 20, further including a disposable film attached to theplurality of non-mechanically connected unidirectional fibers via thepartially-cured resinous material to keep adjacent fiber layers within aroll from attaching to each other.
 23. The repair kit of claim 20,wherein the plurality of non-mechanically connected unidirectionalfibers are non-mechanically connected by the resinous material forming amatrix that bonds the unidirectional fibers together such that there isno other connection between the unidirectional fibers.
 24. A method ofmaking the repair-kit of claim 1 to be used for reinforcing physicalstructures, comprising: moving the plurality of non-mechanicallyconnected unidirectional carbon fibers through the resinous material fordeveloping a moisture-curable polymer; permitting the resinous materialto only partially cure such that plurality of fibers are adheredtogether to form a flexible fiber layer; placing the fiber layer withinan enclosure of the repair-kit package that is substantiallymoisture-free; and sealing the enclosure while the resinous materialremains in a partially-cured state and in a substantially moisture-freeenvironment.
 25. The method of claim 24, further including winding thefiber layer around a spool prior to placing the fiber layer within theenclosure.
 26. A method of reinforcing a physical structure using therepair kit of claim 1, comprising: removing a fiber layer from amoisture-tight package, the fiber layer includes the plurality ofnon-mechanically connected unidirectional carbon fibers adhered togetherthrough the resinous material that is in a partially-cured state at thetime of removal from the moisture-tight package, the resinous materialbeing a polyurethane; applying the fiber layer to a surface of thephysical structure such that the fiber layer adheres to the surface dueto the partially-cured state of the resinous material; and addingmoisture to the fiber layer to transition the resinous material into afully-cured state and to harden the fiber layer on the surface of thephysical structure.
 27. The method of claim 26, wherein the resinousmaterial is an aliphatic isocyanate-functionalized polyurethaneprepolymer in the partially-cured state.